Devices, systems, and methods for recovery and recycling of carpet components

ABSTRACT

Devices, systems and methods for the recycling and recovery of carpet are disclosed herein. Devices, systems and methods for disassembling carpet into the various components used for carpet construction by abrasive removal and separation of components are also disclosed herein.

CLAIM OF PRIORITY

This application is a continuation of U.S. patent application Ser. No.13/324,798, filed Dec. 13, 2011, now U.S. Pat. No. 8,408,968, whichclaims the benefit of U.S. Provisional Patent Application Nos.61/422,323, filed Dec. 13, 2010 and 61/528,569, filed Aug. 29, 2011. Theentire contents of the foregoing applications are hereby incorporated byreference herein.

TECHNICAL FIELD

The present disclosure relates generally to the recycling and recoveryof carpet. Certain embodiments relate more specifically to devices,systems, and methods for disassembling carpet into the variouscomponents used for carpet construction by abrasive removal andseparation of components.

BRIEF DESCRIPTION OF THE DRAWINGS

The written disclosure herein describes illustrative embodiments thatare non-limiting and non-exhaustive. Reference is made to certain ofsuch illustrative embodiments that are depicted in the figures, inwhich:

FIG. 1A is a cross sectional view of an exemplary cut pile carpet 50that may be processed by the methods and systems disclosed herein. Thiscross sectional view illustrates the cut pile face fibers 20 protrudingfrom the primary backing 30 and a secondary backing 40 that is attachedto the bottom surface of the primary backing 30.

FIG. 1B is a further illustration of the primary components of the cutpile carpet 50 depicted in FIG. 1A.

FIG. 2 is a cross sectional view of an exemplary loop pile carpet 50that may be processed by the methods and systems disclosed herein. Thiscross sectional view illustrates the loop pile face fibers 20 protrudingfrom the primary backing 30 and a secondary backing 40 that is attachedto the bottom surface of the primary backing 30.

FIG. 3 is a cross sectional view of an exemplary carpet 50 with looppile and cut pile face fibers 20 that may be processed by the methodsand systems disclosed herein.

FIG. 4 is a side view of an exemplary carpet recycling system,illustrating a first high speed abrasive drum 202 applying pressureagainst a carpet 50 held in tension along the outer radius of theprimary drum 100. The secondary backing 40 of the carpet 50 is removedas the first high speed abrasive drum 202 spins and applies pressureagainst the carpet 50.

FIG. 5 is a side view of an exemplary carpet recycling system,illustrating an abrasive circular rotating device 210 applying pressureagainst a carpet 50 held in tension along the outer radius of theprimary drum 100. The secondary backing 40 of the carpet 50 is removedas the abrasive circular rotating device 210 spins and applies pressureagainst the carpet 50.

FIG. 6 is a side view of an exemplary carpet recycling system,illustrating a second high speed abrasive drum 204, a primary drum 100,and a carpet 50 (without a secondary backing 40) held in tension overthe outer radius of the primary drum 100. The face fibers 20 of thecarpet 50 are plucked from the primary backing 30 as the second highspeed abrasive drum 204 spins and applies pressure against the facefibers 20.

FIG. 7 is a schematic diagram of an exemplary carpet recycling system,illustrating a set of high speed abrasive drums 200 (also shown as afirst high speed abrasive drum 202 and a second high speed abrasive drum204), a primary drum 100, a plurality of rollers 400 positioned alongthe outer radius of the primary drum 100, and a carpet 50 attached to aretention mechanism 105 on the primary drum 100.

FIG. 8 is a side view of an exemplary carpet recycling system,illustrating a small ramp 110 affixed to the outer edge of the primarydrum 100 for easing the second high speed abrasive drum 202 into firstcontact with the carpet 50.

FIG. 9 is a side view of an exemplary carpet recycling system,illustrating a downward facing carpet 50 held in tension by a retentionmechanism 105 and a plurality of rollers 400 positioned along the outerradius of a primary drum 100, while the secondary backing 40 of thecarpet 50 is abraded by the first high speed abrasive drum 202.

FIG. 10 is a side view of an exemplary carpet recycling system,illustrating an upward facing carpet 50 (without a secondary backing 40)held in tension by a retention mechanism 105 and a plurality of rollers400 positioned along the outer radius of a primary drum 100, while facefibers 20 are being plucked from the primary backing 30 by the secondhigh speed abrasive drum 204.

FIG. 11 is a flowchart illustrating an embodiment of the methods forcarpet recycling described herein.

FIG. 12 is a schematic view of an embodiment of a carpet recyclingsystem as described herein.

FIG. 13 is a perspective view of an embodiment of an assembled highspeed abrasive drum 200 fitted with an abrasive material 205 that isspirally wrapped around the high speed abrasive drum 200.

FIG. 14 is a perspective view of the high speed abrasive drum 200 fromFIG. 13 prior to assembly.

FIG. 15 is cross sectional view of the head end of an embodiment of ahigh speed abrasive drum 200.

FIG. 16 is a cross sectional view of the tail end of an embodiment of ahigh speed abrasive drum 200.

DETAILED DESCRIPTION

Devices, systems, and methods for recycling carpet 50 are describedherein. The methods, systems and devices disclosed are suited tobreaking down post-consumer carpet 50 into components that havesignificant value as recycled materials. The methods described hereininclude placing the carpet 50 under tension and separating the materialcomponents of the carpet 50 by abrasion. For example, in certainembodiments, the carpet 50 is placed under tension, the secondarybacking 40 is removed from the primary backing 30 by abrasion, and theface fiber 20 is abrasively stripped from the primary backing 30. Insuch an embodiment, the face fiber 20, primary backing 30 and thesecondary backing 40 materials can be isolated during the recyclingprocess and, if desired, further processed for use as post-consumermaterials.

FIGS. 1-3 illustrate cross sectional views of cut pile and loop pilecarpets 50 that can be processed by the methods and systems for carpetrecycling described herein. The carpets 50 shown in FIGS. 1-3 includecut pile face fibers 20 or loop pile face fibers 20, a primary backing30, and a secondary backing 40. These carpets 50 include a plurality ofcut pile face fibers 20 or loop pile face fibers 20 protruding from thetop surface of the primary backing 30. The secondary backing 40 formsthe bottom surface of the carpet 50, is adhered or connected to theprimary backing 30, and includes one or more fillers 60 and one or moreadhesives 70.

The term “face fibers” refers to fibers or yarns made of any one of anumber of types of materials, e.g., acrylics, nylons, polypropylene,polyethylene, polyamides, polyesters, wool, cotton, rayon, and the like,that are or can be used to form the pile of a cut pile or loop pilecarpet 50.

The term “primary backing” is used herein to refer to a woven ornon-woven fabric made of one or more natural or synthetic fibers oryarns such as wool, polypropylene, polyethylene, ethylene-propylenecopolymers, polyesters, rayon, and the like. The face fibers 20 of thecarpet 50 are affixed to and/or through the primary backing 30.

The term “secondary backing” is used herein to refer to woven ornon-woven fabrics made of one or more natural or synthetic fibers oryarns such as wool, polypropylene, polyethylene, ethylene-propylenecopolymers, polyesters, rayon, jute and the like. The secondary backing40 is generally affixed or adhered to the primary backing 30.

The terms “filler” and “fillers” are used herein to refer to substancessuch as calcium carbonate, glass, coal fly ash, bauxite, calciumsulfite, and the like, which are suitable for use in the manufacture ofcarpets 50.

The terms “adhesive” and “adhesives” are used herein to refer tosubstances such as latex and the like, which are suitable for use in themanufacture of carpets 50.

The methods described herein comprise breaking down carpet 50 into itsprimary components by abrasion. As used herein, “primary component”refers to any of the face fiber 20, the primary backing 30, and thesecondary backing 40. The term “abrasion” refers to any technique,process, or technology involving the application of an abrasive to thesurface of a material with a mechanical force sufficient to abrade,grind, strip, pull, or otherwise remove the designated component,surface, or layer. For purposes of the present disclosure, “abrasion”includes any sanding or grinding technique, process, or technologysuitable for use in the methods described herein for separating carpet50 into its primary component materials. In certain embodiments,abrasion as contemplated for the methods described herein is carried outusing an abrasive drum, an orbital, reciprocating or circular sander,grinding wheels or grinding wheels mounted or stacked onto a shaft,abrasive wire wheels or shafts, or a belt sanding or grinding mechanism.The abrasive material 205 may be a suitable, commercially availableabrasive product, such as, sandpaper, abrasive cloth, abrasiveparticles, hook and loop roll abrasive cloth, and the like. In oneembodiment, abrasive particles may be applied to, adhered to, orembedded within the surface of a drum or shaft for use in abrasion ascontemplated for the methods described herein. In an alternativeembodiment, abrasive particles may be applied to, adhered to, orembedded within the surface of a removable sleeve that can slide or bedisposed over the surface of a drum or shaft for use as an abrasivematerial 205.

In the methods described herein, carpet 50 to be recycled is provided,the secondary backing 40 is removed by abrasion, and the face fibers 20are stripped from the primary backing 30 by abrasion. Once separatedfrom the carpet 50, the materials forming the primary components may beseparately collected for recycling. Therefore, by facilitating theseparate collection of the materials forming each of the primarycomponents, the methods described herein greatly facilitate collectionof the individual components for recycling, minimize cross-contaminationof the recovered materials, and reduce or eliminate the need for furtherprocessing of primary component materials prior to their subsequentsale, transport, or use.

In some embodiments, the carpet 50 to be recycled may be cleaned orremediated prior to abrasively breaking down the carpet 50 into itsprimary components. In further embodiments, the carpet 50 is sizedand/or sorted prior to abrasive deconstruction. For example, in someembodiments, the carpet 50 may be graded according to the nature of theface fiber 20 as part of the recycling process. Grading the carpet 50 inthis manner reduces the possibility of cross-contamination of face fiber20 materials recovered from the methods described herein. For example, asystem for carrying out the methods described herein may be dedicated torecycling carpets 50 having a certain type or class of face fibers 20.Alternatively, a single system may be used for recycling carpets 50having any type of face fiber 20, but the carpets 50 may be graded,grouped, and processed according to face fiber 20 type so that differenttypes of face fibers 20 can be collected with little or no contaminationwith face fibers 20 of a different material.

In certain embodiments, the materials forming the primary components maybe further processed to facilitate their sale, transportation, or use aspost-consumer recycled materials. For instance, the materials may bewashed, or otherwise cleaned, densified, pelletized, baled, etc.Moreover, in some embodiments, once separated from the carpet 50, theprimary component materials may be handled or processed to isolate orproduce secondary component materials. For example, the secondarybacking 40 may include fiber 42, adhesive 70, and filler 60 materials,and once separated from the carpet 50, the material forming thesecondary backing 40 may be collected and processed in a manner thatisolates one or more secondary component materials (e.g., one or more ofthe fiber 42, adhesive 70, or filler material 60 recovered from thesecondary backing 40). Therefore, in certain embodiments of the methodsdescribed herein, the material recovered from the secondary backing 40is processed to isolate one, or more, or each of the adhesive 70, filler60, and fiber 42 materials used in the secondary backing 40. Forexample, the material recovered from the secondary backing 40 may befurther processed using a hammer mill, attrition mill or shredder beforebeing separated using a vibratory screen, air cyclone, hydro cyclone,float/sink tank or other suitable separation device or devicesconfigured for use in this context.

To facilitate abrasive removal of the secondary backing 40 and strippingof the face fibers 20 from the primary backing 30, in certainembodiments of the methods described herein, a force is applied to thecarpet 50 to prevent significant folding, wrinkling, or deflection ofthe carpet 50 upon application of the abrasive materials 205 and/orforces. As used herein, a “significant” folding, wrinkling, ordeflection of the carpet would include any condition that prevents thehigh speed abrasive drum 200 from making full and flat contact with thecarpet 50 during processing.

In certain embodiments, prior to abrasive deconstruction, the carpet 50may be immobilized at one or more ends or surfaces. Such immobilizationmay be carried out using any suitable retention mechanism 105, such as,for example, a clamp, a vice, or other mechanical fixing means, such asone or more hooks or pins. Alternatively, the carpet 50 may beimmobilized by sewing multiple pieces of carpet 50 end-to-end forming acontinuous roll, which is prevented from turning by using a conventionalbraking mechanism, thus, keeping the carpet 50 taut and flat duringprocessing. Immobilization of the carpet 50 at one or more ends orsurfaces reduces or eliminates folding, wrinkling or deflection of thecarpet 50 during processing.

In addition to being immobilized at one or more ends or surfaces, insome embodiments, a tensile force may be additionally applied to thecarpet 50. In certain such embodiments, the tensile force is applied ina single direction (e.g., parallel to the length or width of the carpet50 being recycled), while in other embodiments, tensile forces may beapplied in two or more directions (e.g., a first tensile force appliedparallel to the length of the carpet 50 and a second tensile forceapplied parallel to the width of the carpet 50). Again, placing thecarpet 50 under one or more tensile forces works to minimize oreliminate issues associated with folding, wrinkling, or deflection ofthe carpet 50 as it is broken down into its primary components byabrasion. In certain embodiments, a tensile force is applied parallel tothe warp yarn of the secondary backing 40. In other embodiments, atensile force is applied parallel to the weft yarn of the secondarybacking 40. In still other embodiments, a first tensile force is appliedparallel to the weft yarn of the secondary backing 40 and a secondtensile force is applied parallel to the warp yarn of the secondarybacking 40. The magnitude of the tensile force(s) applied to the carpet50 may vary depending on the size and nature of the carpet 50 to berecycled.

FIG. 11 is a flowchart schematically illustrating an embodiment of themethods for recycling carpet 50 as described herein. The method maystart with inspection of the carpet 50 to determine if a hazardouscontaminant, such as, for example, asbestos, is present. If a hazardousmaterial is present, steps can be taken to abate the hazardous materialand, if needed, properly dispose of the carpet 50 without furtherprocessing. If a hazardous material is not present, the carpet 50 may bechecked for other non-hazardous contaminants and cleaned, if necessary.If the carpet 50 is cleaned to remove contaminants, the carpet 50 may bere-inspected after cleaning to ensure that all contaminants aresufficiently removed before further processing.

Once it is confirmed that the carpet 50 is free of hazardous materialand sufficiently clean, the face fiber type of the carpet 50 may bedetermined so as to properly sort the carpet 50 for further processingwith other like carpets 50. The face fiber type of the carpet 50 may bedetermined using commercially available tools and systems such as amicro-fiber carpet analyzer, such as a Polychromix Phazir™ analyzer, andthe like. Once sorted according to the type of face fiber 20, the carpet50 may be measured and combined according to size in preparation for theabrasive breakdown of the carpet 50. As described herein, the secondarybacking is removed by abrasion. In particular embodiments describedherein, once the secondary backing is removed, the face fibers areremoved by abrasion. Removal of the secondary backing prior to removaland separation of the face fibers eases recovery of the face fibers,allows recovery face fibers that are substantially free of contaminantmaterials from the secondary backing, and can simplify collection of theprimary backing. For example, abrasive removal of the secondary backingfollowed by abrasive removal of the face fiber results in a primarybacking that is substantially intact and substantially or completelyfree of face fiber or secondary backing materials.

Embodiments of devices and systems suited to recycle carpet 50 accordingto the methods described herein are illustrated in and described inassociation with FIGS. 4-10 and FIGS. 12-16. Though the methods andsystems described herein are illustrated in FIGS. 4-10 and FIGS. 12-16,it is to be understood that the methods described herein are not limitedto the embodiments illustrated. For example, mechanical means differentthan those specifically illustrated herein for securing the carpet to berecycled while the secondary backing and primary backing materials areremoved can be assembled and configured to recycle carpet as describedherein.

The system illustrated in FIGS. 4-10 includes a primary drum 100 and oneor more high speed abrasive drums 200. The carpet 50 is mounted to theprimary drum 100, with at least one end of the carpet 50 immobilized. Aplurality of rollers 400 positioned along the outer radius of theprimary drum 100 applies at least one tensile force to hold the carpet50 in place. The one or more spinning high speed abrasive drums 200 maybe applied against the carpet 50 to abrasively separate the carpet 50into its primary component materials. At least one high speed abrasivedrum 200 may be applied against the carpet 50 to remove the secondarybacking 40 from the primary backing 30. The aggregate mixture 45 (e.g.,abraded secondary backing fibers 42, adhesives 70, and fillers 60) iscollected by a collection system 500, which may include one or more of avacuum system 510, one or more filters, a cyclone system, a vibratoryscreen, and the like. The collection system 500 may be used to furtherseparate the aggregate mixture 45 into its secondary components. Thecarpet 50 may be turned over and at least one high speed abrasive drum200 may be applied against the face fibers 20 to separate the facefibers 20 from the primary backing 30. Similarly, the face fibers 20separated from the primary backing 30 may be collected by a collectionsystem 500, which may include one or more of a vacuum system 510, one ormore filters, a cyclone system, a vibratory screen, a face fiber packingsystem, and the like.

FIG. 4 illustrates a side view of a first high speed abrasive drum 202and primary drum 100. Shown in FIG. 4 is a primary drum 100, the radiusof the primary drum 100 (represented by R_(D)), a first high speedabrasive drum 202, an abrasive material 205, a carpet 50, and anaggregate mixture 45. An aggregate mixture 45 may include abradedsecondary backing fibers 42, adhesives 70, and/or fillers 60 that areremoved from the bottom surface of a carpet 50 by at least one highspeed abrasive drum 200. The primary drum 100 may be configured toreceive and secure carpet 50 with the secondary backing 40 facingtowards the first high speed abrasive drum 202. One or more tensileforces (represented by force arrows F₁) may be applied to hold thecarpet 50 along the outer radius of the primary drum 100. The first highspeed abrasive drum 202 may include or be fitted with an abrasivematerial 205, and pressure (represented as force arrow F₃) may beapplied by the first high speed abrasive drum 202 against the carpet 50to remove the secondary backing 40. After the secondary backing 40 isabraded from the primary backing 30, the carpet 50 may be turned over sothat the face fibers 20 are positioned to come into contact with atleast one high speed abrasive drum 200 in preparation for stripping theface fibers 20 from the primary backing 30. In embodiments of the systemillustrated in FIGS. 4-10, and where the carpet 50 is affixed to theprimary drum 100 at one end, turning the carpet 50 over may beaccomplished by reversing the rotational direction of the primary drum100.

FIG. 5 illustrates an alternative to the one or more high speed abrasivedrums 200. In particular, as shown in FIG. 5, a circular rotatingabrasive device 210 may be used as an alternative to a high speedabrasive drum 200. Shown in FIG. 5 is a primary drum 100, the radius ofthe primary drum 100 (represented as R_(D)), a circular rotatingabrasive device 210, and an abrasive material 205. The primary drum 100may be configured to receive and secure a carpet 50 with the secondarybacking 40 facing the circular rotating abrasive device 210. The carpet50 may be held in tension along the outer radius of the primary drum100. The circular rotating abrasive device 210 may be fitted with anabrasive material 205, and pressure (represented as force arrow F₃) maybe applied by the circular rotating abrasive device 210 against thecarpet 50 to separate the secondary backing 40 from the primary backing30 of the carpet 50. After the secondary backing 40 is abraded from theprimary backing 30, the carpet 50 may be turned over so that the facefibers 20 are positioned to come into contact with at least one highspeed abrasive drum 200 in preparation for stripping the face fibers 20from the primary backing 30. In embodiments of the system illustrated inFIGS. 4-10, and where the carpet 50 is affixed to the primary drum 100at one end (shown in FIGS. 7-10 and FIG. 12), turning the carpet 50 overmay be accomplished by reversing the rotational direction of the primarydrum 100.

As illustrated in FIGS. 4 and 5, removal of the secondary backing 40with abrasion results in an aggregate mixture 45 of abraded secondarybacking fiber 42, adhesive 70, and filler 60 materials. Once separatedfrom the primary backing 30, the aggregate mixture 45 may be collectedand processed in a manner that isolates one or more secondary componentmaterials (e.g., secondary backing fiber 42, adhesive 70, and filler 60materials). In certain embodiments described herein, the aggregatemixture 45 may be captured and separated into its secondary componentsby a collection system 500, including any combination of a vacuum system510 (shown in FIG. 12), one or more filters, a cyclone system, avibratory screen, or any other physical or mechanical separation device.

In one embodiment, a vacuum system 510 may be used to collect theaggregate mixture 45 released from the abrasion and a cyclone system maybe used to transfer the aggregate mixture 45 to a vibratory screen. Thevibratory screen may be used to separate the aggregate mixture 45 intoits secondary components materials. Where a vacuum system 510 is used tocollect the aggregate mixture 45 released from the abrasion, the vacuumsystem 510 may be configured to facilitate the mechanical separation ofthe secondary backing fiber 42 from adhesive 70 and filler 60 materials.For example, the conduit within which a vacuum is generated may includeone or more drops, chutes, or openings (not shown) where larger-sized orheavier materials (such as, e.g., a collection of secondary backingfiber 42) will drop away and separate from lighter adhesive 70 andfiller 60 materials as they are pulled through the vacuum system 510 tobe collected (such as by a cyclone collection system). Alternatively orin addition, in certain embodiments, a vacuum system 510 may include oneor more filters sized and configured to separate one or more of thesecondary component materials included in the aggregate mixture 45. Forexample, the vacuum system 510 may include a filter, screen, sieve,mesh, or other suitable mechanism configured to capture and collect oneor more of the secondary backing fibers 42 or the adhesive 70 and filler60 materials. The vacuum systems 510 described herein may include acyclone system that is configured to collect or further separate theaggregate mixture 45 collected by the vacuum system 510 and receivedinto the cyclone system. In order to generate the negative pressurewithin the vacuum system, an inline fan suitable for pulling theaggregate mixture 45 through the vacuum system 510 may be used.

FIG. 6 illustrates the carpet 50 after removal of the secondary backing40 and after the carpet 50 has been turned over to expose the facefibers 20 to a second high speed abrasive drum 204 for furtherprocessing. Shown in FIG. 6 is a primary drum 100, the radius of theprimary drum 100 (represented by R_(D)), a second high speed abrasivedrum 204, an abrasive material 205, and a plurality of face fibers 20woven into a primary backing 30. The primary backing 30 may be held byat least one tensile force (represented by force arrows F₂) along theouter radius of the primary drum 100 with the face fibers 20 facing thesecond high speed abrasive drum 204. As pressure (represented as forcearrow D₂) is applied by the spinning second high speed abrasive drum 204against the face fibers 20 of the carpet 50, the second high speedabrasive drum 204 abrasively removes the face fibers 20 from the topsurface of the primary backing 30. The second high speed abrasive drum204 may be similar or identical in construction and/or operation to thefirst high speed abrasive drum 202.

In certain embodiments, the second high speed abrasive drum 204 may alsobe an orbital, reciprocating or circular sander, or a belt sanding orgrinding mechanism. Abrasive removal of the face fibers 20 from theprimary backing 30 results in separated face fibers 20, which may becaptured with a collection system 500. In certain embodiments, theseparated face fibers 20 may be collected and processed by a collectionsystem 500, including any combination of a vacuum system 510, a cyclonesystem, a face fiber packing system, and the like. In one embodiment,the separated face fibers 20 may be delivered to a container 520 from acyclone or a vacuum system. Depending upon the final disposition of theface fibers 20, the face fibers 20 may be cleaned or further processed.In some embodiments, the face fibers may be densified, pelletized, orbaled.

FIG. 7 schematically illustrates an exemplary carpet recycling systemaccording to one aspect of the present description. Shown in FIG. 7 is aset of high speed abrasive drums 200 (shown as a first high speedabrasive drum 202 and a second high speed abrasive drum 204), one ormore screeds 410, one or more sensors 415, a primary drum 100, aretention mechanism 105 affixed to the primary drum 100, and a pluralityof rollers 400. As shown, carpet 50 is being loaded onto the carpetrecycling system in preparation for removal of the secondary backing 40.The carpet recycling system can be configured to permit manual loadingof carpet 50 onto the primary drum 100, or the system can be configuredto provide automatic loading of carpet 50, such as by the inclusion of aconveyor and loading system (not shown) configured to automatically loadcarpet 50 onto the primary drum 100. In certain embodiments, the carpet50 may be oriented and loaded onto the primary drum 100, such that thewarp yarn follows the outer radius of the primary drum 100, while theweft yarn lies perpendicular to the outer radius of the primary drum100. Where the secondary backing 40 includes polypropylene yarns,generally, the warp yarn is relatively shiny in appearance, while theweft yarn, which retains relatively more filler 60 and adhesive 70material is relatively dull. The edges of the carpet 50, which may becut and/or squared prior to processing, may be secured to the primarydrum 100 using a retention mechanism 105 (for example, the retentionmechanisms described herein) to hold the carpet 50 in place as theprimary drum 100 rotates in a direction that allows the secondarybacking 40 to face away from the primary drum 100.

As the primary drum 100 rotates to pull carpet 50 through the pluralityof rollers 400 and along the outer radius of the primary drum 100, therollers 400 apply a force against the carpet 50 to maintain tension andto remove wrinkles and creases that may be present. One or morepneumatic cylinders may be connected or otherwise attached to theplurality of rollers 400 along the outer radius of the primary drum 100to apply a force that pulls the plurality of rollers 400 against theprimary drum 100. In certain embodiments, the force applied to the oneor more pneumatic cylinders is selected from approximately 20 to 500pounds per square inch; approximately 20 to 250 pounds per square inch;approximately 20 to 150 pounds per square inch; approximately 20 to 100pounds per square inch; approximately 50 to 500 pounds per square inch;approximately 50 to 250 pounds per square inch; approximately 50 to 150pounds per square inch; and approximately 50 to 100 pounds per squareinch. In a specific embodiment, the force applied to the one or morepneumatic cylinders is approximately 80 pounds per square inch. In oneembodiment, the force applied by the rollers 400 to hold the carpet 50in tension ranges from approximately 150 to 1,500 pounds per squareinch. In certain such embodiments the force applied is selected from thefollowing ranges: approximately 250 to 1,500 pounds per square inch;approximately 250 to 1,250 pounds per square inch; approximately 250 to1,000 pounds per square inch; approximately 500 to 1,500 pounds persquare inch; approximately 500 to 1,250 pounds per square inch;approximately 500 to 1,000 pounds per square inch; approximately 750 to1,500 pounds per square inch; approximately 750 to 1,250 pounds persquare inch; and approximately 750 to 1,000 pounds per square inch.

Where a carpet recycling system as described herein includes one or morescreeds 410 to minimize or eliminate folding, wrinkling, or deflectionof the carpet 50 as it approaches the high speed abrasive drums 200, theone or more screeds 410 may be positioned parallel to the plurality ofrollers 400, along the outer radius of the primary drum 100. In someembodiments, the one or more screeds 410 may be situated adjacent toeither or both of the first 202 and second 204 high speed abrasivedrums. The screeds 410 may be constructed from any suitable material,including, but not limited to, steel, aluminum, iron, and the like.

A screed 410 utilized in a carpet recycling system according to thepresent description may be configured such that it has a substantiallyplanar surface that comes into contact with the carpet 50 disposed overthe outer radius of the primary drum 100. In an alternative embodiment,the screed 410 may have a substantially concave surface that may benested against the non-planar cylindrical surface of the primary drum100. A screed 410 will generally be configured such that, by either orboth of its weight or application of a mechanical force to the screed410, the screed 410 applies a desired pressure across the surface of thecarpet 50 that comes into contact with the screed 410. The pressureapplied against the carpet 50 creates an even tension along the carpet50, which further reduces or eliminates wrinkles, creases, ordeflections in the carpet 50 prior to contact with one or more highspeed abrasive drums 200. In certain embodiments, the screed 410 may beattached or otherwise connected to a frame structure (not shown). Infurther embodiments, the screed 410 may be slidably or hingeablyattached to the frame structure, such that the proximity of the screed410 to the carpet 50 disposed over the primary drum 100 may be adjustedaccordingly.

A small ramp 110 (shown in FIG. 8) may be affixed to the outer edge ofeach side of the primary drum 100 to ease the high speed abrasive drums200 into first contact while the carpet 50 is held in tension along theouter radius of the primary drum 100 by the plurality of rollers 400.FIG. 8 illustrates a primary drum 100, a retention mechanism 105, asmall ramp 110, and a first high speed abrasive drum 202 fitted with anabrasive material 205. The small ramp 110 may be affixed to the outeredge of each side of the primary drum 100 and adjacent to the retentionmechanism 105 that is used to secure the edges of the carpet 50 to theprimary drum 100. Small wheels 215 may also be affixed to each side ofthe high speed abrasive drums 200 to ease the high speed abrasive drums200 into first contact with the carpet 50. As illustrated in FIG. 8, thesmall wheels 215 may aid in rolling the first high speed abrasive drum202 onto the small ramp 110, before easing the first high speed abrasivedrum 202 into first contact with the carpet 50. The use of a small ramp110 and wheels 215 on the first high speed abrasive drum 202 may reducethe likelihood of backlash in the primary drum 100 upon first contactand decrease the likelihood of burn through of the carpet duringabrading. The second high speed abrasive drum 204 may be similar oridentical in construction and/or operation to the first high speedabrasive drum 202. The second high speed abrasive drum 204 may alsoinclude small wheels 215 affixed to each side of the second high speedabrasive drum 204 to ease the second high speed abrasive drum 204 intofirst contact with the carpet 50.

In one embodiment, the high speed abrasive drums 200 may be fitted witha pressure-maintaining mechanism (not shown) to maintain a substantiallyeven pressure against the carpet 50 sufficient to effectively separatethe secondary backing 40 and/or face fibers 20 from the primary backing30. Examples of such pressure-maintaining mechanisms may includepneumatic cylinders, coil spring mechanisms, hydraulic cylinders, andthe like.

The speed of the primary drum 100 and the high speed abrasive drums 200,the pressure applied by the high speed abrasive drums 200 against thecarpet 50, the pressure with which the carpet 50 is affixed to theprimary drum 100, and the tension exerted across the carpet 50 by, forexample, the forces applied by the plurality of rollers 400 may beadjusted so as to minimize or prevent uneven or inconsistent removal andisolation of the individual components of the carpet 50 being recycled.For example, one or more of each of these parameters may be adjustedaccording to the characteristics (e.g., thickness, size, density, etc.)and/or nature (e.g., face fiber type, materials used in secondary andprimary backings, etc.) of the carpet 50 being recycled.

In some embodiments, the system may include one or more sensors 415capable of assessing one or more qualities of the carpet 50 beingrecycled, such as the thickness, size, density, face fiber type, andmaterials used in secondary and primary backings, etc. Input receivedfrom such sensors 415 can be used to adjust, as needed, one or moresystem parameters (e.g., the speed of the primary drum 100, the speed ofthe high speed abrasive drums 200, the pressure applied by the highspeed abrasive drums 200 against the carpet 50, the pressure with whichthe carpet 50 is affixed to the primary drum 100, and the tensionexerted across the carpet 50 by, for example, the forces applied by theplurality of rollers 400).

Where one or more sensors 415 are provided, the one or more sensors 415may be positioned in proximity to or in direct contact with the carpet50 to be recycled as the carpet 50 is prepared for, positioned within,or processed by the carpet recycling system. For example, one or moresensors 415 may be positioned and configured to sense the movement ordisplacement of the one or more rollers 400 or the one or more screeds410 positioned along the outer radius of the primary drum 100 to allowadjustment of one or more of the speed of the primary drum 100, thespeed of the high speed abrasive drums 200, and the amount of pressureto be applied against the carpet 50 based on, for example, the size,density, or thickness of the carpet 50. One or more sensors 415 may alsobe positioned and configured to assess the carpet 50 to be recycled asit is loaded into primary drum 100. Any sensor 415 suitable for sensingand communicating information regarding the characteristics and/or thenature of the carpet 50 may be utilized. In particular embodiments, theone or more sensors 415 may be coupled or associated with an automaticor programmable control system capable of automatically adjusting one ormore system parameters in light of information received from the one ormore sensors 415.

The carpet recycling system may also include a drum-aligning means (notshown) to keep the high speed abrasive drums 200 in line with theprimary drum 100. Examples of such drum-aligning means may include agear rack and pinion assembly (not shown), and the like.

FIG. 9 illustrates a side view of the secondary backing 40 being removedby the first high speed abrasive drum 202. Shown in FIG. 9 is a primarydrum 100, a first high speed abrasive drum 202, a second high speedabrasive drum 204, an abrasive material 205, a retention mechanism 105,a screed 410, a sensor 415, and a plurality of rollers 400. As shown inFIG. 9, a carpet 50 is held in tension along the outer radius of aprimary drum 100 by a retention mechanism 105 and a plurality of rollers400, such that the secondary backing 40 of the carpet 50 faces the firsthigh speed abrasive drum 202. A screed 410 may be positioned adjacent tothe first high speed abrasive drum 202 to minimize or eliminate anywrinkles, creases, or deflections in the carpet 50 prior to contact withthe first high speed abrasive drum 202. The primary drum 100 rotatesaround its axis while the first high speed abrasive drum 202 spins andcomes into contact to the carpet 50. The first high speed abrasive drum202 applies a constant pressure against the carpet 50 and operates at aspeed sufficient to effectively remove the secondary backing 40.

The primary drum 100 may be rotated by a rotating means 115 at avariable speed. Examples of such rotating means 115 may include ahydraulic drive, a hydraulic drive and gear reduction system, anelectric drive, an electric drive and gear reduction system, a chaindrive, a chain drive and gear reduction system, a friction drive, afriction drive and gear reduction system, and the like.

In addition, the primary drum 100 may rotate at a variable speedsuitable to effectively separate the secondary backing 40 and/or facefibers 20 from the primary backing 30. The speed at which the primarydrum 100 rotates may vary depending on the size and nature of the carpet50 to be recycled. In one embodiment, the primary drum 100 may rotate ata speed ranging from about 1 to 100 feet per minute. In certain examplesof such an embodiment, the primary drum may rotate at a speed selectedfrom about 2-50 feet per minute, about 2-30 feet per minute, about 2-20feet per minute, about 2-15 feet per minute, about 2-10 feet per minute,about 2-5 feet per minute, about 15-75 feet per minute, about 15-65 feetper minute, about 15-55 feet per minute, about 15-45 feet per minute,about 15-35 feet per minute, about 15-25 feet per minute, about 25-100feet per minute, about 25-75 feet per minute, about 25-65 feet perminute, about 25-55 feet per minute, about 25-45 feet per minute, andabout 25-35 feet per minute. In a particular embodiment, the primarydrum 100 may rotate at a speed ranging from about 18-60 feet per minute(ft/min). In another specific embodiment, the primary drum 100 mayrotate at a speed of 2-3 revolutions per minute (RPM). The pressureapplied to the high speed abrasive drums 200 is directly proportional tothe speed of the primary drum 100, as well as the width of the carpet 50retained in the primary drum 100 and the density of the face fiber 20 ofthe carpet 50.

The speed at which the high speed abrasive drums 200 rotate may bevaried to suit a particular application. In each embodiment, the speedof the high speed abrasive drum 200 is set at a speed that effectivelyremoves the desired carpet component without substantially removing oraltering additional components. For example, the high speed abrasivedrums may be configured to rotate at a speed ranging from about 500-RPMto 10,000-RPM. In certain such embodiments, the high speed drums can beselected and configured to rotate at a range of speeds selected fromabout 500-RPM to 7,500-RPM, about 500-RPM to 5,000-RPM, about 500-RPM to3,500-RPM, about 500-RPM to 2,500-RPM, about 750-RPM to 7,500-RPM, about750-RPM to 5,000-RPM, about 750-RPM to 3,500-RPM, about 750-RPM to2,500-RPM, about 1,000-RPM to 7,500-RPM, about 1,000-RPM to 5,000-RPM,about 1,000-RPM to 3,500-RPM, and about 1000-RPM to 2,500-RPM. In oneembodiment, the high speed abrasive drums 200 may operate at standardmotor speed of 1800-RPM with a one-to-one belt drive. In an alternativeembodiment, the high speed abrasive drums 200 may operate at a speed ofapproximately 4,200 feet per minute.

The amount of force to be applied by the high speed abrasive drums 200fitted with pressure-maintaining mechanisms depends on, for example, theamount and qualities (e.g., the characteristics, such as thickness,size, density, etc., and/or nature, such as face fiber type, andmaterials used in secondary and primary backings, etc.) of the carpet 50being processed. The amount of pressure applied by the high speedabrasive drums may also be adjusted according to the speed at which thehigh speed abrasive drums 200 and the primary drum 100 rotate. Incertain embodiments, the high speed abrasive drums apply a forceselected from the following ranges: approximately 2 to 50 pounds offorce per inch of carpet width retained by the primary drum 100;approximately 2 to 35 pounds of force per inch of carpet width retainedby the primary drum 100; approximately 2 to 25 pounds of force per inchof carpet width retained by the primary drum; approximately 2 to 20pounds of force per inch of carpet width retained by the primary drum100; approximately 2 to 15 pounds of force per inch of carpet widthretained by the primary drum 100; and approximately 2 to 10 pounds offorce per inch of carpet width retained by the primary drum 100. Inother embodiments, the high speed abrasive drums apply a force selectedfrom the following ranges: approximately 4 to 50 pounds of force perinch of carpet width retained by the primary drum 100; approximately 4to 35 pounds of force per inch of carpet width retained by the primarydrum 100; approximately 4 to 25 pounds of force per inch of carpet widthretained by the primary drum; approximately 4 to 20 pounds of force perinch of carpet width retained by the primary drum 100; approximately 4to 15 pounds of force per inch of carpet width retained by the primarydrum 100; and approximately 4 to 10 pounds of force per inch of carpetwidth retained by the primary drum 100. In still further embodiments, Inother embodiments, the high speed abrasive drums apply a force selectedfrom the following ranges: approximately 2 to 8 pounds of force per inchof carpet width retained by the primary drum 100; approximately 2 to 7pounds of force per inch of carpet width retained by the primary drum100; approximately 2 to 6 pounds of force per inch of carpet widthretained by the primary drum; approximately 2 to 5 pounds of force perinch of carpet width retained by the primary drum 100; approximately 4to 8 pounds of force per inch of carpet width retained by the primarydrum 100; approximately 4 to 7 pounds of force per inch of carpet widthretained by the primary drum 100; approximately 4 to 6 pounds of forceper inch of carpet width retained by the primary drum 100; andapproximately 4 to 5 pounds of force per inch of carpet width retainedby the primary drum 100. In a specific embodiment, the high speedabrasive drums 200 apply approximately 4 to 6 pounds of force per inchof carpet width retained by the primary drum 100 operating atapproximately 3-RPM.

The high speed abrasive drums 200 may also be attached or otherwiseconnected to a frame structure. In one embodiment, the high speedabrasive drums 200 may be hingeably or slidably attached to the framestructure (not shown), such that the proximity of the high speedabrasive drums 200 to the primary drum 100 can be adjusted accordingly.In certain embodiments, the high speed abrasive drums 200 may connectedto the same frame structure (not shown) that is connected to the one ormore screeds 410.

Abrasive material 205 may be selected from any material suitable forabrading or sanding that is sufficiently flexible to wrap around a highspeed abrasive drum 200, including sandpaper, carbide grit, diamondgrit, zirconium grit, abrasive cloth, hook and loop roll abrasive, andthe like. In one embodiment, the abrasive material 205 comprisesabrasive particles ranging from one of approximately 10-200 grit, 10-100grit, 10-75 grit, 10-65 grit, 10-50 grit, 10-25 grit, 15-200 grit,15-100 grit, 15-75 grit, 15-65 grit, 15-50 grit, 15-25 grit, 20-200grit, 20-100 grit, 20-75 grit, 20-65 grit, 20-50 grit, and 20-25 grit.In a specific embodiment, the abrasive material 205 comprises abrasiveparticles ranging from approximately 24-60 grit. The high speed abrasivedrums 200 may be machined out of a solid steel shaft and balanced toaccommodate smooth operation at high speed, such that the abrasivematerial 205 can be quickly and easily replaced while maintaining drumbalance and, therefore, low vibration, which works to provide improvedbearing life and relatively low cost of operation. In an alternativeembodiment, the high speed abrasive drums 200 may be replaced with oneor more grinding wheels, one or more abrasive wire wheels or shafts, oneor more shafts containing abrasive particles applied to, adhered to, orembedded within the surface of the one or more shafts, one or moreshafts with removable sleeves containing abrasive particles applied to,adhered to, or embedded within the surface of the removable sleeves, orother suitable abrasive means that are configured for use in thiscontext.

FIG. 10 illustrates a side view of face fibers 20 being separated fromthe primary backing 30 by a second high speed abrasive drum 204. Shownin FIG. 10 is a primary drum 100, a first high speed abrasive drum 202,a second high speed abrasive drum 204, a retention mechanism 105, ascreed 410, a sensor 415, and a plurality of rollers 400. As shown inFIG. 10, the secondary backing 40 of the carpet 50 from FIG. 9 has beenabraded by the first high speed abrasive drum 202. The rotationaldirection of the primary drum 100 may be reversed and the carpet 50turned over to expose the face fibers 20. A screed 410 may be positionedadjacent to the second high speed abrasive drum 204 to reduce oreliminate any wrinkles, creases, or deflections that may be present inthe carpet 50 prior to contact with the second high speed abrasive drum204. As the primary drum 100 rotates around its axis, the second highspeed abrasive drum 204 spins and comes into contact with the carpet 50.The second high speed abrasive drum 204 applies a substantially constantpressure against the carpet 50 as it spins at a speed sufficient toeffectively remove the face fibers 20 from the primary backing 30.

FIG. 12 provides a schematic illustration of an embodiment of a systemsuited to the methods for deconstructing and recycling carpet 50 asdescribed herein. The system embodiment illustrated in FIG. 12illustrates that the methods described herein are suited to the stepwiseremoval and recovery of the primary components of the carpet 50 beingrecycled. With reference to FIG. 12, with the carpet 50 secured at oneend in the primary drum 100, the primary drum 100 is rotated such thatthe secondary backing 40 of a carpet 50 faces out and the carpet 50 ispulled under the one or more rollers 400, which work to maintain thecarpet 50 in position against the primary drum 100 and under tension asthe primary drum 100 rotates. As the carpet 50 passes the first highspeed abrasive drum 202 fitted with an abrasive material 205, thesecondary backing 40 is removed from the primary backing 30, resultingin an aggregate mixture 45 of secondary components (e.g., abradedsecondary backing fiber 42, adhesive 70, and filler 60 materials). Incertain embodiments described herein, the aggregate mixture 45 may becollected and separated into its secondary components by a collectionsystem 500, which may include any combination of one or more vacuumsystems 510, one or more filters, one or more cyclone systems, one ormore vibratory screens, or any other physical or mechanical separationdevice.

In one embodiment, a vacuum system 510 may be used to collect theaggregate mixture 45 released from the abrasion, and a cyclone systemmay be used to transfer the aggregate mixture 45 to a vibratory screen.The vibratory screen may be used to separate the aggregate mixture 45into its secondary component materials. Where a vacuum system 510 isused to collect the aggregate mixture 45 released from the abrasion, thevacuum system 510 may be configured to facilitate the mechanicalseparation of the secondary backing fiber 42 from adhesive 70 and filler60 materials. For example, the conduit within which a vacuum isgenerated may include one or more drops, chutes, or openings (not shown)where larger-sized or heavier materials (such as, e.g., a collection ofsecondary backing fiber 42) can drop away and separate from lighteradhesive 70 and filler 60 materials, as they are pulled through thevacuum system to be collected (such as by a cyclone collection system).Alternatively or in addition, in certain embodiments, a vacuum systemmay include one or more filters sized and configured to separate the oneor more secondary component materials included in the aggregate mixture45. The vacuum system may include one or more of a filter, screen,sieve, mesh, or other suitable mechanism configured to capture andcollect one or more of the secondary backing fibers 42 or the adhesive70 and filler 60 materials. The vacuum systems 510 described herein mayinclude a cyclone system configured to collect or further separate theaggregate mixture 45 collected by the vacuum system 510 and receivedinto the cyclone system. In one embodiment, the vacuum systems 510described herein or any other suitable mechanisms, such as a conveyorbelt, may be used to transfer the one or more secondary componentmaterials separated from the aggregate mixture 45 into one or moredesignated containers 520 for collection or further processing, asdesired, for sale, transportation, or use.

In one embodiment, a vacuum system 510 may be used to collect the facefiber 20 released from abrasion, and a cyclone system may be used totransfer the face fiber 20 to a vibratory screen to remove any residualprimary backing 30 or secondary backing components. The cyclone systemdescribed herein may also be used to transfer the face fibers 20 to adesignated container 520 for collection or further processing, asdesired, for sale, transportation, or use. Alternatively or in addition,in some embodiments, a cyclone system or another suitable system, suchas a conveyor system, may be used to transport the face fibers 20 to apacking system to be densified, pelletized, and/or baled.

Where a vacuum system is used herein as part of a collection system, inorder to generate the negative pressure within the vacuum system 510, aninline fan suitable for pulling the aggregate mixture 45 through thevacuum system 510 may be used. The inline fan can be positioned, asdesired, within the vacuum system 510 to generate a negative pressure topull the aggregate mixture 45 through the vacuum system 510. To increasesystem reliability and operational life of the inline fan, the inlinefan can be positioned within the vacuum system 510 such that contactbetween the inline fan and primary or secondary component materials isprevented or minimized. In one embodiment, the inline fan is positionedwithin the vacuum system 510 such that one or all of the primary orsecondary component materials is collected prior to reaching the inlinefan.

Once the secondary backing 40 is removed, the face fiber 20 of thecarpet 50 is then stripped by abrasion from the primary backing 30. Inthe embodiment of the system illustrated in FIG. 12, the carpet 50 isprepared for stripping of the face fibers 20 by turning the carpet 50over so that the face fibers 20 face out. With the system shown in FIG.12, turning the carpet 50 over can be accomplished by reversing thedirection of rotation of the primary drum 100, resulting in the carpet50 being pulled through the one or more rollers 400 such that theprimary backing 30 is positioned against the primary drum 100 and theface fibers 20 are positioned to come into contact with the second highspeed abrasive drum 204 fitted with an abrasive material 205. The secondhigh speed abrasive drum 204 may be similar in construction andoperation to the first high speed abrasive drum 202. As the primary drum100 rotates in the direction opposite to that used for removal of thesecondary backing 40, the face fibers 20 come into contact with thesecond high speed abrasive drum 204, resulting in the face fibers 20being stripped from the primary backing 30. Again, a vacuum system 510may be used to collect the separated face fibers 20 and a cyclone systemmay be used to transfer the separated face fibers 20 to a container 520for collection or further processing, as desired, for sale,transportation, or use. Depending upon the final disposition of the facefibers 20, the face fibers 20 may be, for example, densified,pelletized, and/or baled.

Once the secondary backing 40 and the face fibers 20 are removed, theprimary backing 30 is removed from the primary drum 100. At this point,the primary backing 30 is essentially free of secondary backing 40 andface fiber 20 materials. The primary backing 30 can then be collected byany suitable means and processed, as desired, for sale, transportation,or use. Depending upon the final disposition of the face fibers 20, theface fibers 20 may be, for example, densified, pelletized, and/or baled.

Though the system illustrated in FIG. 12 is just one embodiment of asystem suited for recycling carpet 50 according to the presentdescription, FIG. 12 highlights that the methods described herein notonly break carpet 50 down into the materials forming the primary carpetcomponents, but the methods described herein also allow for thecollection of the materials forming each of the primary components asdiscrete products. The materials collected include littlecross-contamination. For example, the face fibers 20 collected includelittle to no material from the secondary backing 40 or primary backing30. Additionally, the recovered primary backing 30 material includeslittle to no face fiber 20 or secondary backing 40 material. Each of thediscrete products produced by the methods and systems described hereincan, itself, be sold, transported, and used with little to no additionalprocessing.

FIGS. 13 and 14 illustrate a perspective view of an exemplary embodimentof a high speed abrasive drum 200 that can be used in the systems andmethods described herein. The high speed abrasive drum 200 is configuredfor receiving and securing an abrasive material 205 onto a high speedabrasive drum 200. As illustrated in FIGS. 13 and 14, the high speedabrasive drum 200 may be configured such that it has an abrasiveretainer 600 on the head end and an adjustable sleeve 610 on the tailend. The adjustable sleeve 610 may also be configured to have anabrasive retainer 600. The abrasive retainer 600 may include a retainingstrip 605, a machined slot 615, and a fastening mechanism 625. Examplesof such fastening mechanisms 625 may include screws, pins, and the like.The retaining strip 605 and fastening mechanism 625 may be inserted intothe machined slot 615 located on the head end of the high speed abrasivedrum 200 to secure one end of the abrasive material 205 in place. Theabrasive material 205 may be wrapped around the high speed abrasive drum200 toward the tail end. The loose end of the abrasive material 205 maybe secured to the tail end of the high speed abrasive drum 200 byinserting the retaining strip 605 and fastening mechanism 625 into themachined slot 615 of the adjustable sleeve 610. The adjustable sleeve610 may be fitted and secured over the tail end of the high speedabrasive drum 200 using a fastening mechanism 625.

FIG. 15 illustrates a cross-sectional view of the head end of a highspeed abrasive drum 200. Shown in FIG. 15 is a high speed abrasive drum200, a retaining strip 605, a fastening mechanism 625, and an abrasivematerial 205. The retaining strip 605 and fastening mechanism 625 securean edge of the abrasive material 205 in the machined slot 615 of thehigh speed abrasive drum 200. The length of the abrasive material 205may be wrapped around the high speed abrasive drum 200 toward the tailend.

FIG. 16 illustrates a cross-sectional view of the tail end of a highspeed abrasive drum 200. Shown in FIG. 16 is a high speed abrasive drum200, an adjustable sleeve 610, a retaining strip 605, an abrasivematerial 205, and fastening mechanisms 625. The clamp strip 605 and afastening mechanism 625 secure an edge of the abrasive material 205 inthe machined slot 615 of the adjustable sleeve 610. The adjustablesleeve 610 may also be attached to the high speed abrasive drum 200using a fastening mechanism 625.

Any methods disclosed herein comprise one or more steps or actions forperforming the described method. The method steps and/or actions may beinterchanged with one another. In other words, unless a specific orderof steps or actions is required for proper operation of the embodiment,the order and/or use of specific steps and/or actions may be modified.

The materials recovered using the methods, systems, and devicesdescribed herein can be used for any purpose suited to the materialrecovered. Because the methods described herein facilitate the removaland isolation of individual components of the carpet 50 being recycled,the methods reduce the amount of additional processing required toprepare the materials for commercial sale and use as recycled materialsfor any one of a variety of applications. In some embodiments, where theprimary components used to construct the carpet 50 are fabricated fromsynthetic yarns or fibers that exhibit lipophilic properties, thematerials generated from the methods and systems described herein arewell suited for use in the recovery, clean-up, and recycling of liquidhydrocarbons and organic liquids. Examples of suitable fibers exhibitinglipophilic properties suitable for recovery, clean-up, and recycling ofliquid hydrocarbons and organic liquids include synthetic fibers, suchas polymer fibers. These polymer fibers may be formed from one or moreof nylon, polyester, olefin, or acrylic polymers.

With reference, for example, to FIG. 12, where any of the primarybacking 30, the secondary backing 40, or the face fibers 20 are formedof a lipophilic material, the recovered lipophilic material may be usedto form absorbent booms, bales, mats, pads, or filling suited for therecovery, clean-up, and recycling of liquid hydrocarbons and organicliquids. In most carpets 50 manufactured, at least one of the primarycomponents is formed using a synthetic yarn or fiber. For example, theyarns used in forming the secondary 40 and primary 30 backings are oftenmade of polypropylene (an olefin polymer). Additionally, the face fiber20 material is typically one of polypropylene, nylon-6, nylon-6.6,polyethylene terephthalate (PET), polytrimethyl terephthalate (PTT),acrylic fibers, and the like. In one example, because the primarybacking 30 recovered using the systems and methods described herein isoften preserved substantially intact, the recovered primary backing 30may be sewn or otherwise formed into the exterior netting of a mat, pad,bale, or boom, with the exterior netting formed by the recovered primarybacking 30 material being filled with one or more of recovered facefiber 20, recovered secondary backing fiber 42, and recovered primarybacking 30 fiber. In specific embodiments, such a mat, pad, bale, orboom would be configured to allow water to pass through while liquidhydrocarbon or liquid organic material contained in the water iscollected in the matrix formed by the recovered lipophilic fibermaterial. Examples of mats, pads, bales, and booms that may beconstructed using the materials recovered from the methods and systemsdescribed herein are shown, for instance, in U.S. Pat. Nos. 3,565,257,3,667,608, 3,679,058, 3,968,041, 5,165,821, 5,580,185, 5,679,247,6,143,172, and 6,743,367, the entire contents of which are hereinincorporated by reference.

Throughout this specification, any reference to “one embodiment,” “anembodiment,” or “the embodiment” means that a particular feature,structure, or characteristic described in connection with thatembodiment is included in at least one embodiment. Thus, the quotedphrases, or variations thereof, as recited throughout this specificationare not necessarily all referring to the same embodiment.

Similarly, it should be appreciated that in the above description ofembodiments, various features are sometimes grouped together in a singleembodiment, figure, or description thereof for the purpose ofstreamlining the disclosure. This method of disclosure, however, is notto be interpreted as reflecting an intention that any claim requiresmore features than those expressly recited in that claim. Rather,inventive aspects lie in a combination of fewer than all features of anysingle foregoing disclosed embodiment. It will be apparent to thosehaving skill in the art that changes may be made to the details of theabove-described embodiments without departing from the underlyingprinciples set forth herein.

1. A method for carpet recycling, the method comprising: removing thesecondary backing of the carpet with abrasion; and removing the facefiber of the carpet with abrasion.
 2. A method of claim 1, wherein themethod further comprises holding the carpet in tension.
 3. A method ofclaim 2, wherein the carpet is held in tension along the outer radius ofa primary drum.
 4. A method of claim 3, wherein the carpet is held intension by a force, and wherein the force applied is selected from oneof the following ranges: approximately 150 to 1,500 pounds per squareinch; approximately 250 to 1,500 pounds per square inch; approximately250 to 1,250 pounds per square inch; approximately 250 to 1,000 poundsper square inch; approximately 500 to 1,500 pounds per square inch;approximately 500 to 1,250 pounds per square inch; approximately 500 to1,000 pounds per square inch; approximately 750 to 1,500 pounds persquare inch; approximately 750 to 1,250 pounds per square inch; andapproximately 750 to 1,000 pounds per square inch.
 5. A method of claim4, wherein the primary drum rotates at a speed selected from one of thefollowing ranges: about 1 to 100 feet per minute; about 2-50 feet perminute; about 2-30 feet per minute; about 2-20 feet per minute; about2-15 feet per minute; about 2-10 feet per minute; about 2-5 feet perminute; about 15-75 feet per minute; about 15-65 feet per minute; about15-55 feet per minute; about 15-45 feet per minute; about 15-35 feet perminute; about 15-25 feet per minute; about 18-60 feet per minute; about25-100 feet per minute; about 25-75 feet per minute; about 25-65 feetper minute; about 25-55 feet per minute; about 25-45 feet per minute;and about 25-35 feet per minute.
 6. A method of claim 2, whereinremoving the secondary backing or the face fiber of the carpet withabrasion comprises applying at least one high speed abrasive drumagainst the carpet.
 7. A method of claim 6, wherein the at least onehigh speed abrasive drum operates at a speed selected from one of thefollowing ranges: about 500-RPM to 10,000-RPM; about 500-RPM to7,500-RPM; about 500-RPM to 5,000-RPM; about 500-RPM to 3,500-RPM; about500-RPM to 2,500-RPM; about 750-RPM to 7,500-RPM; about 750-RPM to5,000-RPM; about 750-RPM to 3,500-RPM; about 750-RPM to 2,500-RPM; about1,000-RPM to 7,500-RPM; about 1,000-RPM to 5,000-RPM; about 1,000-RPM to3,500-RPM; and about 1000-RPM to 2,500-RPM.
 8. A method of claim 6,wherein the at least one high speed abrasive drum applies a force ofapproximately 4 to 6 pounds per inch of carpet width against the carpet.9. A system for carpet recycling, the system comprising: a primary drum,wherein the primary drum is configured to receive a carpet disposed overthe outer radius of the primary drum; and at least one high speedabrasive drum, wherein the at least one high speed abrasive drum isconfigured to remove at least one of the secondary backing and the facefibers of the carpet with abrasion.
 10. A system of claim 9, wherein theat least one high speed abrasive drum comprises at least one of a firsthigh speed abrasive drum, wherein the first high speed abrasive drum isconfigured to remove the secondary backing of the carpet with abrasion;and a second high speed abrasive drum, wherein the second high speedabrasive drum is configured to remove the face fiber of the carpet withabrasion.
 11. A system of claim 10, the primary drum comprising at leastone clamping mechanism configured to secure carpet against the primarydrum.
 12. A system of claim 11, wherein the primary drum rotates atapproximately 2-3 RPM.
 13. A system of claim 10, the system furthercomprising a plurality of rollers, wherein the rollers are positionedalong the outer radius of the primary drum.
 14. A system of claim 11,wherein the plurality of rollers deliver a constant force ofapproximately 1,000-pounds against the primary drum.
 15. A system ofclaim 10, wherein the at least one high speed abrasive drum furthercomprise a pressure-maintaining mechanism, wherein thepressure-maintaining mechanism applies a constant force on the at leastone high speed abrasive drum.
 16. A system of claim 15, wherein the atleast one high speed abrasive drum is fitted with an abrasive material.17. A system of claim 16, wherein the abrasive material compriseabrasive particles ranging from approximately 24-60 grit.
 18. A systemof claim 17, wherein the at least one high speed abrasive drum spins ata speed of approximately 4,200 ft per min.
 19. A system of claim 18,wherein the at least one high speed abrasive drum applies a force ofapproximately 4 to 6 pounds per inch of carpet width against the carpet.20. A system of claim 19, the system further comprising at least onevacuum system extending towards the at least one high speed abrasivedrum to collect at least one of aggregate mixture and separated facefibers.
 21. A system of claim 20, the system further comprising at leastone cyclone system and at least one vibratory screen, wherein the atleast one vibratory screen separates the aggregate mixture.
 22. A deviceuseful in the recovery, clean-up or recycling of liquid hydrocarbons andorganic liquids, the device comprising lipophilic fibers obtained fromthe method of claim
 1. 23. The device of claim 22, wherein the fiberscomprise a synthetic material selected from one or more of nylon,polyester, olefin, or acrylic polymers.
 24. The device of claim 22configured as an absorbent mat, pad, boom or bale comprising acontainment layer formed by a first material, wherein the first materialis permeable to water and is lipophilic in nature, and a fillermaterial, wherein the filler material is contained by or positionedwithin the containment layer, is also permeable to water, and islipophilic in nature.
 25. The device of claim 24, wherein the firstmaterial is formed by selecting from fibers obtained from removing thesecondary backing of a carpet with abrasion, fibers obtained fromremoving the face fiber of a carpet with abrasion, and fibers obtainedfrom a primary backing of a carpet after removing the secondary backingand face fibers by abrasion.
 26. A method for producing a device usefulin the recovery, clean-up or recycling of liquid hydrocarbons andorganic liquids, the method comprising: providing lipophilic fibersobtained from the method of claim 1; providing a containment layer;forming a filler material comprising the lipophilic fibers; assembling adevice comprising the filler material contained by or positioned withinthe containment layer, wherein the device is configured as an absorbentmat, pad, boom or bale that is permeable to and allows the passage ofwater, while absorbing or otherwise collecting liquid hydrocarbons andorganic liquids that come in contact with the filler material.
 27. Themethod of claim 26, wherein providing lipophilic fibers comprisesproviding fibers obtained from removing the secondary backing of acarpet with abrasion.
 28. The method of claim 26, wherein providinglipophilic fibers comprises providing fibers obtained from removing theface fibers of a carpet with abrasion.
 29. The method of claim 26,wherein providing lipophilic fibers comprises providing fibers from theprimary backing of a carpet after removing the secondary backing andface fibers by abrasion.
 30. The method of claim 26, wherein providing acontainment layer comprises providing a containment layer comprising thelipophilic fibers obtained from a method for carpet recycling, whereinthe method for carpet recycling comprises removing the secondary backingof the carpet with abrasion, and removing the face fiber of the carpetwith abrasion.